JPS601433B2 - Asphalt impregnated felt building material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to building materials, particularly asphalt-impregnated paper felts, and more particularly to an asphalt-impregnated felt backing together with an asphalt-bound inorganic filler mixture layer applied onto the backing and optionally It relates to the so-called asphalt scale type with a reflective (and possibly decorative) finely divided stone finish coating applied onto outdoor exposed surfaces.

This type of asphalt scale is the most common roofing material used throughout North America for private residential buildings today, and its effectiveness as a weatherproof finish (especially for pitched roofs), durability And it is popular because of its low cost. As used herein, the term "paper felt" refers to a felt fabric or textile material suitable for impregnation and optional application with asphalt-based impregnation agents and paints to form building materials. This means all of the porous webs. Due to the recent sharp increase in the cost of petroleum products, including asphalt grades used in asphalt felt construction materials, materials that can at least partially replace the asphalt grades used in building materials, especially asphalt scales, have been developed. Research has been carried out.

Generally, two different grades of asphalt are used in roofing manufacturing. The first is a felt dipper grade used to impregnate the felt backing material, which provides the material with primary tensile strength and tear resistance. The second are coating grades that are generally enriched with inert inorganic fillers to produce a coating that provides durability to the roofing material. Representative (but not exclusive) property ranges for several impregnant grades of asphalt available on the market are shown in Table 1 as defined by the American Roofing Manufacturers Association (ARMA). shown. Table 1 - Felt building soaking agents Representative (but not exclusive) property ranges for several coating grades of asphalt currently used in roofing materials are given in Table D', also as defined by ARMA}.
This is shown.

Table □ - Covering asphalt Mixtures of the above and other grades of asphalt, now used in building materials, with sulfur, in a mixture of 10 - 55% by weight
It has been found that the available asphalt can be expanded and used for the formation of an impregnating or coating material having all the necessary properties for the production of building materials, in particular asphalt-type roofing scales, in a proportion of And, quite surprisingly, it has been found that materials made from such sulfur asphalt mixtures have significantly higher flame resistance or fire resistance than materials made from the same asphalt without sulfur.

Thus, the present invention provides an impregnated felt building material comprising a web of paper felt, in which the web is 90-45%
Impregnating agent of 10%-5 dispersed in asphalt
240o -3500 in a homogeneous dispersion composition of 5% sulfur
F(1150-17600) and then remove the impregnating agent on the web surface to remove at least 14% by weight of the soaked felt into the web, preferably 160-260
The present invention relates to the above-mentioned soaked felt building material, characterized in that it has been pressed to leave a residual soaking agent of % by weight.

The present invention further comprises a felt backing impregnated with a river asphalt-based impregnation agent and a mineral-filled binder mixture applied thereon, wherein the binder for the mineral filler is 90-45 wt. The invention relates to an asphalt roof shingle characterized in that it is a sulfur asphalt homogeneous dispersion composition comprising 10-55% by weight of sulfur dispersed in 10% by weight of coating asphalt. Ratios and percentages herein are by weight unless otherwise specified. Mixtures of elemental sulfur and roofing grade and similar grades of asphalt include liquid sulfur in fluid asphalt at a desired ratio at substantially 3500F (176C).
Obtained by blending under appropriate soul cutting conditions at the following temperatures so that sulfur is dispersed in asphalt,
Adequate cutting action is achieved using high-speed sintering machines, propeller mixers, pipeline mixers, and other conventionally designed high-sliding mixing equipment of appropriate size for the amount of material to be mixed. obtain. It is well known that sulfur thus dispersed in asphalt dissolves in and/or homogeneously combines with the asphalt in proportions of up to substantially 15-25% by weight of the mixture. The proportions that can be so homogeneously distributed depend primarily on the nature of the asphalt. When a larger proportion of liquid sulfur is blended with fluid asphalt, the excess of the homogeneously dispersed proportion becomes dispersed heterogeneously as droplets of liquid sulfur in the fluid asphalt, and the mixture This condition continues until the total amount of sulfur in the mixture is substantially 50-6% by weight, above which the mixture reverses to a dispersion of fluid asphalt in liquid sulfur. Therefore, sulfur proportions substantially above 55% by weight, based on the sum of sulfur and asphalt, are inappropriate and excluded from the invention. Upon cooling of the heterogeneous dispersion of sulfur droplets in fluid asphalt, the sulfur solidifies or crystallizes and remains dispersed as small particles dispersed throughout the asphalt. Examples are provided below to illustrate various features of the invention.

The sulfur asphalt mixture used in these examples consists of approximately 250 grams of 3000F (14900) fluid asphalt in a metal container that is placed on a 1500 watt electric hot plate and further heated with electrical heating tape wrapped around the outside. obtained by incorporating liquid sulfur into the liquid sulfur, and when this liquid sulfur is also added, the
000F (149C) and the amount added to the asphalt varies depending on the ratio of sulfur in the desired formulation, i.e. 10, 21 or 5 to the formulation as shown in the specific example.
Adjustments were made to obtain a proportion of 0% by weight. Initially, dispersion of sulfur into asphalt was accomplished by mixing for 1-2 minutes using a 1/2 horsepower (373 watt) turbine mixer with a high-speed acid cutter operating at 5000-700 pm. . After several blends, the proper blend is a pressure of 10
A laboratory-grade "
Lightnin (trade name) model ARL
It has been found that this can be achieved by mixing for 2-5 minutes using an air-operated mixer. This resulted in a suitable dispersion of sulfur in asphalt in which the diameter of the sulfur droplets was substantially all less than 50 microns and the average sulfur droplet size was 1-10 microns. The temperature of the formulation was adjusted to 3000 ± 100F (1490
The temperature was controlled at 5℃). Example 1 In this example, the impregnation of dry felt material was carried out to form co-impregnated felts with various sulfur asphalt mixtures.

The felt thus formed is used as a built-up roof panel (BUR).
as roofing felt in the construction of and for asphalt scales which may be coated on one side with a mineral-filled asphalt basecoat and optionally surfaced with mineral granules, mineral-filled on one side. Backing material for asphalt roll-type roofing material coated with an asphalt basecoat and optionally surfaced with inorganic granules, and coated on one side with a mineral-filled asphalt basecoat and optionally with mineral granules It was of the type suitable as a backing material for asphalt roll-type wallboards finished with an asphalt surface. The example also shows that compared to a combustible felt impregnated with ordinary impregnant asphalt,
This shows that sulfur asphalt-containing eel felt has flame retardancy. In the examples, unsoaked dried paper felt samples were used for impregnation of sulfur asphalt formulations or regular asphalt.

The asphalt used had a specific gravity of 1.0209 at 600F (1SO) and a flash point (ASTM method D92).
) 5200F (27ro), Penetration (PEN) 35 (ASTM Method D5) at 77°C (2500) and Ring and Ball Softening Point 1490F by ASTM Method D36
(6500) was an impregnant grade commercial refinery asphalt. Mix some of this asphalt with liquid sulfur and heat to 3,000 degrees and 100F (149 degrees and 5℃).
A batch of sulfur asphalt soaking agent was prepared by forming a formulation containing 25% sulfur in the formulation, which formulation was carried out using the heat and air operated hawker equipment described above. Visual microscopic measurements of random samples of this formulation show that the sulfur is homogeneously dispersed after several minutes of mixing, with an average sulfur vial size of less than 10 microns and virtually all sulfur droplets having a diameter of 50 microns. It turned out to be smaller than a micron. A 0.019 inch (0.48 inch) thick 12 inch (30.4 inch) square sheet sample of dry powder impregnated felt was placed in an approximately 3000 F (14900) asphalt or sulfur asphalt mix for approximately 49 mm. Impregnation was done by hand dipping and simulated the conditions of passing a continuous web of felt over rollers in a thickening tank.The liquid was allowed to drip on the sheet for 15 seconds and then the sheet was
The dry felt sheet is heated to 180-200°C by placing it between hydraulic machine platens heated to a temperature of 180-200°C (104°C - 121°C), where pressure is applied to squeeze out excess impregnant. An impregnated felt containing % by weight of impregnating agent was obtained. These impregnated felts were comparable to commercially available asphalt-impregnated paper felts used in roofing, except for the composition of the impregnating agent when containing added sulfur. To compare the flame retardancy of the impregnants, a modified combustion test was used using available equipment. Thickness 1'8
A rectangular inverted U-shaped frame was made using yellow steel with a width of 1'2 inches (3.2 sails) and a width of 13 legs. A distance of 2 inches (51 willow) of unobstructed space was maintained between the inside sides of the frame, and a 10 inch (254 skin) distance was maintained from the bottom to the inside of the top of the inverted U-shape. Two frames were attached, one on each side of a 3 x 10 inch (76 skin x 254 willow) sheet of impregnated felt to form a flat specimen with exposed felt edges. The specimen was securely mounted with the frame at a 45° angle and with the exposed felt green side down. To provide a uniform ignition source, a standard Cleverland open cup
A taper from a flash device was used.
Adjust the taper flame to a length of 3 inches (7.6 cm) and place the tip of the taper 2 inches (5c) from the felt surface and 1'2 inches (13 ribs) from the bottom green. Approximately 1
An inch (2.5 c) was allowed to sway over the felt surface. The weight of each sample of material to be ignited was measured before combustion, and after self-extinguishing the weight of the ash and collected retentate of the unburned portion of the sample was measured. It is understood that 1'3 of the sample weight cannot be burned because it is trapped between the side pieces and does not receive the necessary air for combustion, and that only a maximum of 2/3 of each sample is consumed by combustion. Should. (A) Showing the flammability of two felt samples, one sample impregnated with impregnant asphalt and the other impregnated with sulfur asphalt impregnant containing 25% sulfur prepared as described above. To do this, weighed samples of impregnated felt were mounted side by side in a fume cupboard and ignited simultaneously with the same tapered flame, which held 6 quarts of sand against the sample before being removed.

The asphalt-impregnated felt continued to burn for 3 minutes after the flame was removed and burned completely, i.e. all of the exposed felt turned to char and ash, and a significant amount of asphalt dripped from the sample during the test. . The combustion residue was weak and crumbled. From the weight of the collected ash and residue, 67% of the consumable portion of the original sample weight was lost to combustion. In contrast, the sulfur asphalt-impregnated felt burns for only 19.5 seconds after flame removal, and the sample forms expanding char on the sheet surface as combustion proceeds from the bottom edge, leaving felt residue and expanding char. Very little impregnant remained as a complete sheet inside the frame and dripped from the sample during testing. The residual bay weight showed that only 56% of the consumable portion of the sample was lost to combustion. (B) To demonstrate the flammability of thicker felt sheets impregnated as described above, two 12 inch (30.4 cm) square impregnated felt sheets were brought together and placed together in a heated platen. A double thickness impregnated felt was prepared by pressing and laminating.

This impregnation and pressing were carried out as described above. The flammability of two samples each impregnated with an impregnant asphalt and a sulfur asphalt impregnant containing 25% sulfur were compared as described above. When using a twice-thick impregnated felt sample (approximately 0.040 inches or 1.02 ribs), the asphalt-impregnated felt completely burned out and completely disintegrated after 60 seconds of ignition, and the sample weight 72% of the expendable part of the fuel was lost through combustion.

The sulfur asphalt-impregnated felt self-extinguished after burning 85% of the distance to the top of the felt after ignition for 60 seconds, and only 37.5% of the expendable portion of the sample weight was lost to combustion. For comparison with commercially available materials, a 0.035 inch (0.035 in.
．． 8 kalpa ribs), size 3 x 10 inches (7.6 x 25.4
c) of asphalt-moated milled felt (mmedf
A sample of elt) was mounted and fired for 6 stages in the same manner as the previous sample. The sample was completely burnt out and disintegrated within 64 seconds after ignition, with 67% of the expendable portion of the sample weight being lost to combustion. Example 2 To demonstrate that asphalt-type scales made using a mineral-filled asphalt coating with a certain proportion of sulfur have superior flame retardancy than scales that do not contain sulfur in the mineral-filled asphalt coating. 0.035 inch thick (
Various scale plates were prepared by individually layering mineral-filled coatings on commercially available asphalt-impregnated paper felts (0.8 arteries).

The filler used in the coating was commercially available powdered limestone of the type commonly used in asphalt scales. Asphalt shed backing felt was also a commercial product of the type commonly used for asphalt scales, and this one did not have sulfur added to the asphalt shed solution. The asphalt samples used in preparing the various fill coating compositions used in the examples were 600F (15.500)
API specific gravity 6.1 at
Softening point 2170F (103℃) by M method D36
and 77F (2500) by ASTM method D5
It was a commercially available 210Melt coating asphalt having a penetration (PEN, 1009, 5 seconds) of 14. The asphalt samples were individually heated to 300°C and 100F (149°±5°C) in the heating apparatus described above. For asphalt samples to also contain sulfur, 10, 25, or 5% by weight of liquid sulfur, each based on the sulfur asphalt formulation, is added to the appropriate sample at a temperature of 300° to 100 F (149° to 5° C.); Therefore, the temperature of the blend did not rise above the above range during the blending of sulfur and asphalt. To the liquid asphalt or sulfur asphalt formulation at this temperature was added a metered amount of powdered limestone filler, also preheated to the same temperature range, to form a filled coating composition. This was done using the same mixer and at a lower speed than when dispersing the liquid sulfur homogeneously in the asphalt. The mixer rotation speed to most effectively wet the filler with asphalt and with the sulfur asphalt formulation was about 1/10 times lower than that used to disperse the sulfur into the asphalt. The temperature of the filler coating composition is thermostatically controlled during this mixing to 3000±100F (149°C) and the proportion of filler added in each case is 50% of the filler composition.
% by weight. To prepare the scale plate samples, a 12 x 14 inch (
Place a 30.5 x 35.6 mm piece on the lower jaw of a 50 ton hydraulic machine to a thickness of approximately 0.085 inch (25 mm).
200 grams of the hot-fill coating composition, roughly spread by pouring between the metal spreaders on side 1), were filled. Next, this combination is ``.Teflon''
)'' (trade name) plastic coated quick release paper and the jaws of the hydraulic machine were closed to apply 10 tons (9100k9) pressure to the assembly for 5 minutes. During the preparation and pressing of the scale plates thus formed, the jaws of the hydraulic machine are
The temperature was maintained at 200±100F (1040±5℃). After being removed from the hydraulic machine, the scale plate was placed in cold water to remove the quick release paper and the substrate. Measure the thickness of the scute at the point of the species and place an appropriate 3 x 10 inch (76.5 x 2 sail) plate with a substantially uniform 0.085 inch (2.15 sail) thickness.
54 willow) pieces were cut and used as test samples for flammability evaluation. These specimens were comparable to equal-sized specimens cut from commercial asphalt roofing scales coated with a 50% mineral-filled asphalt coating, except for the composition of the mineral-filled coating, which contained added sulfur. Ta. To compare the flammability of the various samples, they were sequentially mounted in the test frame described in the example above and ignited for 60 seconds using a standard taper as described above. Some of the samples were weighed before ignition and their residual weights after self-extinguishing were collected and measured to determine weight loss during the test. Visual inspection of the scales after self-extinguishing showed that the pure asphalt scales burned easily after ignition and were almost completely burnt out after a single ignition. A large amount of asphalt was observed dripping from the undergreen during the test. The asphalt scales had almost no original shape after burning, and the felt paper backing had numerous cracks and holes caused by burning. In contrast, scales with sulfur asphalt formulations within the coating produce an expanding layer of char at the base of the frame as combustion progresses, which layer extinguishes the flame more rapidly and removes the charcoal from the scales. It is believed that this helps prevent asphalt from flowing out, and in most cases it takes 2-3 ignitions due to the taper to complete combustion.
After the combustion was completed, the scales still had their original shape and no holes caused by burning. In order to maintain objectivity of the results, many combustion tests were performed simultaneously in pairs using adjacent replicate frames and tapers, thus ensuring that any type of scute specimen would not be sidetracked by a sideways test. This ensured that the results were not skewed. The weight loss at the end of combustion, expressed as a percentage of the expendable portion of the scale weight, is the best indication of the fire resistance of the samples in these comparisons, with lower weight loss indicating the best fire resistance. Scale samples without sulfur in the covering asphalt binder lose 67%-85% of their expendable weight at the end of combustion, while scale samples with 10% sulfur in the covering binder lose 67%-85% of their expendable weight at the end of combustion. Losing 33%-47% of its consumable weight at termination, a scale sample with 25% sulfur in the coating binder loses approximately 30% and loses 50% sulfur in the coating binder. It was observed that the containing scale plate sample lost only about 13% of its expendable weight at the end of combustion. As an additional sample comparison to demonstrate the importance of weight loss due to combustion and the relative combustion resistance of scales containing sulfur in asphalt coatings, coatings oxidized in the presence of 0.3% ferric chloride. Samples of commercial oxidized asphalt were used to prepare scale samples as described above, and these scale samples did not contain added sulfur in the binder coating. (Commercial asphalt scales made with cover asphalt oxidized with FeC13 are rated as Class A for roofs by fire insurance carriers, but
Conventional commercial asphalt scales made of normally oxidized coating asphalt are given a Class B rating only. ) Scale plate samples made as described herein using FeC13 oxidized coating asphalt were
It was found that it loses 52-57% of its expendable weight at the end of combustion as described in the above tests. Thus, scales containing as little as 10% sulfur in the asphalt coating binder exhibited higher flame resistance than comparable scales with a Class A fire rating guarantee. Example 3 This example shows the superiority of asphalt-type scales in which the impregnating agent in the felt hair material and the binder in the filler coating each contain 25% sulfur and 75% asphalt.

A sulfur asphalt soaking agent formulation was prepared exactly as in Example 1, and then an impregnated felt thickness of 0.040
Example 1 [B}' is a laminated sample sheet of inch (1.02 skin).
This was prepared as described. Next, apply Example 2 to the impregnated sheet.
Exactly the same 'strain, with 25% sulfur and 21% sulfur in the binder.
A 50% mineral-filled coating with 75% asphalt was applied to a thickness of approximately 0.085 inches (2
．． A sample sheet of 15 ribs was obtained. A substantially homogeneous 3 x 10 inch (7.6 x 25.4 cm) piece, 0.085 inch (2.15 ribs) thick, cut from this sample was then mounted as in the previous example. 6 Inkstone Sunama was lit. After the ignition period, the flame burned to 3 inches (7.6 skins) above the specimen within 6 seconds before extinguishing. A wide expanding charcoal formed at the base of the flame as combustion spread through the specimen. The weight loss during the first combustion was 3.6%. In order to maintain combustion, a tapered flame was kept continuously against the scale plate and the sample was re-ignited, and the sample finally finished burning. The weight loss at the end of combustion was only 23.2% of the expendable part of the sample. - Comparing this with Example 2, the scale plate in Example 2 which contains 25% sulfur and 75% asphalt in the binder of the filler coating but no sulfur in the impregnated asphalt of the backing material is consumed at the end of combustion. It is noted that about 30% of the weight that could be lost was lost. In addition to the samples and specimens prepared and tested as described in the examples above, many other samples and specimens were prepared and tested in the materials in impregnation agents for mineral-filled asphalt coatings or impregnated felts. was used to evaluate other properties of asphalt-type roof villages in which part of the asphalt was replaced with sulfur. Such evaluations include accelerated weathering evaluations in an Atlas Physical property measurements and an environmental assessment were included to assess potential air pollution problems posed by added sulfur. Such evaluation revealed that no harmful properties were produced by adding sulfur to the sample. Depending on the proportion of sulfur in the liquid sulfur asphalt formulation, sulfur can be substantially 2300F (110
oo) reduce the viscosity of liquid materials at temperatures above, thus allowing the use of lower temperatures in material handling, mixing and application. As such, prior art mineral-filled asphalt coatings are generally applied to scale plates at somewhat higher temperatures, e.g., about 3500F (17500), and paper felts are generally applied at even higher temperatures, e.g. Although the asphalt is impregnated, sulfur asphalt formulations are most conveniently prepared and applied at temperatures of about 300°C (1490°C). It is not prohibited to use it. If you are prepared to install and use pollution abatement equipment to remove sulfur-related contaminants,
Temperatures higher than 9o±5°C may be used. In the above examples, various roofing materials of the type based on webs of asphalt-impregnated paper felt are described and in the formulation 1
It has been shown that homogeneous blends of sulfur and the corresponding asphalt containing 0-55% by weight sulfur can be used in place of the impregnating asphalt or both used in such materials.

Claims (1)

Claims: 1. In an impregnated felt building material having an asphalt-based impregnant and optionally an inorganic filler asphalt-based binder mixture applied thereon, the asphalt-based impregnant in the felt and At least one of the asphalt-based binders is a homogeneously dispersed composition of 10%-55% sulfur dispersed in 90%-45% asphalt, and any sulfur not dissolved in the asphalt in the composition is 50%-45% asphalt. Said impregnated felt building material, characterized in that it is dispersed as finely divided particles of size smaller than microns. 2 Contains a paper felt web, and the web has a diameter of 90
%-45% impregnating agent in a homogeneous dispersion composition of 10%-55% sulfur dispersed in asphalt.
soaked at a temperature of 350°F (115°-176°C) and then pressed to remove the impregnant on the web surface and leave residual impregnant in the web at least 140% by weight of the unimpregnated felt. Impregnated felt building material according to claim 1, characterized in that: 3 The impregnating agent is 160-260% by weight of the unimpregnated felt.
The impregnated felt building material according to claim 2, which is 4. The building material comprises (a) a felt backing impregnated with an asphalt-based impregnant, and (b) a mineral-filled binder mixture applied thereon, the binder for the mineral filler comprising: Claim 1, characterized in that the asphalt roof shingle is a sulfur asphalt homogeneous dispersion composition containing 10-55% by weight of sulfur dispersed in 90-45% by weight of coating asphalt. impregnated felt building material. 5. Impregnated felt building material according to claim 4, wherein the impregnating agent in the felt is a sulfur asphalt homogeneous blend comprising 10-55% by weight of sulfur and 90-45% by weight of impregnating asphalt.